Discardable cap construction with adjustable brim



Feb. 18, 1958 E. J. DE'vlLLERs 2,823,387

DISCARDABLE CAP CONSTRUCTION WITH ADJUSTABLE BRIM Filed Sept. 6, 1955 2 Sheets-Sheet 1 INVENTOR E J ADe: .Villers @Pull out fo Head Size lllan'lnvvhdruaulnnunl..

ATTORNEY Feb. 18, 1958 E. J. DE VILLERS DISCARDABLE CAP CONSTRUCTION WITH ADJUSTABLE BRIM 2 Sheets-Sheet 2 Filed Sept. 6, 1955 INVENTOR Ef e Villers vBY ATTORNEY United States Patent() DISCARDABLE CAP CONSTRUCTION WITH ADJUSTABLE BRllVI `Edmund J. De Villers, Columbus, Ohio, assignor, by

mesne assignments, to Paperlynen Company, Columbus, Ohio, a corporation of Ohio This invention aims primarily to provide inexpensive machine-made caps, or other similar articles of head wear.

Another aim of the invention is to provide caps formed from low-cost materials, such as paper or the like, and so formed as to be susceptible to manufacture through the use of automatic machinery, in order that the unit cost of such caps will be sufiiciently low to admit of the complete discarding thereof when the same become soiled or otherwise impaired through use.

A further aim of the invention is to provide a paper cap wherein an improved brim construction is provided admitting of circumferential adjustment thereof in adapting the cap to the various head sizes of wearers.

A still further aim of the invention is to provide an improved article of head wear so formed that it may be atly folded in association with other corresponding articles -for compactness in shipment and storage, the articles being so designed that they may be readily opened or expanded for application to the heads of wearers, and when worn will present an attractive military appearance, well adapted for use by either men or women.

The invention also contemplates other details of construction as will hereinafter more fully appear.

The illustrated embodiments of the invention will now be described and thereafter the invention pointed out in the claims.

In the drawings:

Fig. l is a view showing in fiat form the shape of the composite blank from which the cap of the present invention is formed;

Fig. 2 is a transverse vertical sectional view taken on the line 2-2 of Fig. l;

Fig. 3 is a view similar to Fig. l but showing the compositeblank 'after the first step of folding the same into cap-forming order has been effected;

Fig. 4 is a transverse sectional view on the line 4 4 of Fig. 3;

Fig. 5 is a View similar to Figs. l and 3 but disclosing the appearance of the composite blank after a second folding step has been performed thereon;

Fig. 6 is a transverse sectional view on the line 6-'6 of Fig. 5;

Fig. 7 discloses the blank 'after a third folding step has been performed thereon;

Fig. 8 is a transverse sectional view on the line 8-8 of Fig. 7;

Fig. 9 is a side View disclosing the cap when fully folded;

Fig. l0 is a vertical transverse sectional view on the line 1010 of Fig. 9; `-ig.11lis a detail longitudinal sectional view on the line `11,'-g11 of Fig. 9; Y W

- Fig; 12 is a perspective view of the'iinished and finally folded cap.

Referring more particularly to the drawings, it will be observed by reference thereto that the cap of the present invention is formed from an elongated generally rectangu- Mice 2 lar blank 10 of paper or the like. The blank is die c ut, or otherwise formed, to provide the same at one side thereof with a head band or brim-forming sectlon 11 and at its other side with a crown-forming section 12. As here shown, the sections 11 and 12 are formed from separate sheets of paper united along their adjoining longitudinally extending edges 13 by an adhesive. This is done in order that the brim section may be formed from a heavier grade of paper than the crown section, so that it will be capable of maintaining through its inherent stiffness a definite shape and, also, to withstand handling and other stresses and strains without ready damage being done thereto. The crown section may be formed from a less expensive and lighter grade of paper, or other felted or woven fiber. It is, also, within the scope of the invention to form the blank 10 from a single, integral sheet of material if desired.

In the formation of the cap, the sections 11 and 12 are usually withdrawn from helically wound reels, not shown, and pass through automatic forming machines in which various operations are performed thereon producing the cap without manual aid.

The cap of the present invention has been especially designed to admit of its formation in automatic machines of this nature, although the same may be formed by hand or with the use of semi-automatic appliances, if desired. As shown in Fig. l, the brim section 11 possesses an elongated rectangular configuration slightly longer than the crown-forming section 12, the same being formed with longitudinally extending crease or fold lines, indicated at 14 and 15, such lines extending inwardly of and in parallel relation to the outer longitudinal edges of the section 11. The material composing the section 11 and disposed between the fold lines 14 and 15, constitutes a brim strip 16. The web of material disposed between the -fold line 14 and the outer longitudinal edge 18 of the section 11, throughout its length, forms the head-engaging strip 17 of the cap. Likewise, the web of material lying between the fold line 15 and the outer longitudinal edge 20 of the section 11, throughout the length of the latter when the same is inwardly folded about the line 15 to lie on the inside and in flat engagement with the outer panel 16, comprises a reinforcing and channel-forming strip 21.

As shown in Figs. 1 and 2, the crown-forming section 12, which is adhesively united at 13 in substantially parallel, longitudinally staggered relationship with one of the longitudinal edges of the strip 11, isformed to include parallel, longitudinally extending marginal edges 22 and 23. The edge portion 23 of the strip 12 overlaps slightly the mating edge portion 18 of the strip 10. This is done in order that the two strips may have their overlapping surfaces firmly united throughout substantially the full length of such overlapping portions by the adhesive applied at the interface. At one end the brim section` 11 and crown section 12 are formed with a crease line 24 extending perpendicularly to the line 14. Between the line 24 and the edge 23, the strip 12 provides a substantially triangular ap 25 having an angularly extending hypotenuse-forming edge 26. At the opposite end of the crown section 12 a complemental and integral triangular flap 27 is formed, having an angular hypotenuse-forming edge 28, the flap 27 being defined by an altitudinal crease line 29 which extendsperpendicularly to the edge 23 and parallel to line 24.

As shown in Fig. 3, the first step in shaping the com! posite blank of Fig. 1 into cap formation consists in folcl-l ing the reinforcing strip 21inwardly along theY crease or fold line 15 so that the same extends throughout its length in contact with the under face of the brim strip 16 of the section 11. After this first folding step, and as shown in Fig. 5, the brim section 11 is folded along the line 14 so that the brim strip 16 will lie adjacent the head strip 17 and the crown section 12. After being so disposed, the

composite blank is Yfolded upon itself along the transversely extending crease line shown at 30 disposed intermediately of the length of .the blank, so that the inner f aces ofthe crown section 12 and the head band 17 will bedisposed in immediately adjoiningcon'tacting order, bringing the triangular flaps 25 and 27 into overlapping or registering contact for adhesive union.

By reference to Figs. 7 and 8, it will be seen that when the composite blank is in the folded condition depicted therein, the outer brim strip 16, the head band strip 17 andthe rein-forcing strip 21 cooperate to form a channel 31 for the telescopic reception of an extension 32. This extension forms a part of the section 11 and is disposed at the right of the triangular flap 25, as the blanks are viewed in Figs. l, 3 and 5. This extension when adjustably positioned in the channel 31 provides a continuous brim or head band which is adjustable to adapt the cap to various head sizes.

For the guidance of the user, there may be printed or otherwise affixed to the inner surface of the head strip 17 suitable indicia 33 indicating head sizes. As the cap is expanded to provide relatively enlarged head sizes, and the extension drawn outwardly of the channel 31, such size indicia is exposed to the view of the user by an inspection of the inside of the cap. Friction normally present between the contacting surfaces of the extension 32 and the walls of the channel 31 serve to maintain the band adjustments thus effected.

As disclosed in Fig. 7, the adjoining upper longitudinal edges 22 of the strip 12 are adhesively united throughout `their length to close the crown portion of the cap and thus close the crown portion of the cap throughout its full area. Also, when the blank is so folded to bring the flaps 25 and 27 into relative registry, the adhesive may be ap- 'plied to their inner adjoining surfaces to firmly unite the same. When so united, the flaps are folded about their registering crease lines 24 and 29 so that the same, as shown in Figs. 9 and 1l, are disposed along one side of the crown region 12 of the finished cap.

In View of the Iforegoing, it will be appreciated that the construction of my improved cap, as defined above, while simple and effective for its purposes, is such that the cap may be readily produced at low cost through machine or other manufacturing operations. The freely telescopic brim or head band construction enables the caps to be readily varied in circumference to meet the head size requirements of various users. The cap when folded for use presents an attractive appearance and possesses sutiicient stiffness and rigidity to maintain its operative form.

Various modifications may be made in the construction of the specific cap illustrated of the drawings without departing from the spirit and scope of the invention, as the latter has been defined in the following claims.

I claim:

q 1. A discardable cap comprising relatively elongated, substantially rectangular crown and brim sections of unequal length disposed in edge-adjoining, parallel relation, said crown section beingfolded longitudinally upon it- Self along a transverse crease line dividing the crown section into opposite continuous side panels of equal area, 'the side panels of said crown section each being formed at one end thereof with relatively coextensively overlying triangular end flaps defined on one side thereof by registering transverse crease lines and said end tiaps being folded backwardly over the outer surface of one of said side panels, the side panels of said crown section and said triangular end flaps being respectively joined together along the outer marginal edges thereof to close said crown section; said brim section being longer than said crown section and having a first end portion vextending a substantial distance longitudinally outwardly beyond a corresponding end of said crown section and a second end portion terminating a distance inwardly from the opposite end of said crown section, the distance between the second end portion of said brim section and the said opposite end of said crown -section being less than the longitudinal extension of the first end portion of said brim section beyond the said corresponding end of said crown section, said brim section being folded transversely upon itself along a pair of spaced longitudinally extending crease lines to provide in said brim section a coextensive channel having closed longitudinal edges and open ends, and said brim section being folded longitudinally upon itself along a transverse crease line coincident to the transverse crease line which divides said crown section, the transverse crease line of said brim section dividing thelatter into opposite side panels of unequal length; the first-named end portion of said brim section being folded adjacent the triangular end flaps of said crown section and being telescoped with the second-named end portion of said brim section, whereby to provide for head size adjustment of said brim section and the triangular end flaps of said crown section upon relative sliding movement of the first and second end portions of said brim section.

2. A cap comprising an elongated substantially rectangular crown section folded backwardly upon itself along a median transverse crease line, dening one end ofthe crown section, and formed at its opposite end with a pair of relatively overlying triangular flap extensions, the backward folding of said crown section providing thereon opposite side panels of equal area, the side panels and the pair of triangular flap extensions of said crown section being respectively secured together along an upper longitudinal marginal edge of said crown section to close the latter, and said pair of triangular flap extensions being both folded backwardly over the outer surface of one of said side panels; and an elongated substantially rectangular head band section joined with said crown section along the longitudinal edge thereof opposite said upper longitudinal marginal edge, said head band section being longer than said crown section and having a first end portion extending longitudinally beyond one end of said crown section and an opposite end portion spaced inwardly from the opposite end of said crown section, the first end portion of said head band section extending longitudinally beyond the corresponding end of said crown section a distance greater than the inward spacing of the said opposite end portion of said head band section from the said opposite end of said crown section, said head band section having marginal edge portions folded inwardly along a pair of relatively spaced longitudinally extending crease lines to define in said head band section a continuous longitudinally extending channel having closed longitudinal edges and open ends, and said head band section being folded backwardly upon itself along a transverse crease line coincident to the rnedian transverse crease line of said crown section, the first end portion of said head band section being folded adjacent the triangular fiap extensions of said crown section'and Atele, scopically inserted within the channel of said head band section at the end thereof opposite said first end portion, the first end portion of said head band section lbeing slidable in the opposite end portion thereof to provide head size adjustment of said head band section and the triangular flap extensions of said crown section.

References Cited in the file of this patent UNITED STATES PATENTS 1,806,225 Vernon May 19, 1931 2,051,084 Hertz Aug. 18, 1936 2,685,090 Wagenfeld Aug. 3, 1954 2,721,329 Berg Oct. 25, `1955 

